Wireless retrievable intelligent downhole production module

ABSTRACT

An apparatus for performing an operation in a borehole penetrating the earth includes a downhole module configured to perform the operation and having an anchor device configured to anchor the module in the borehole, the anchor device being releasable in order to retrieve the module. A power source is disposed on the module and configured to provide power to the module while a signal transducer is disposed on the module and configured to at least one of transmit a wireless signal and receive a wireless signal. The apparatus further includes a downhole electronic device disposed on the module, coupled to the signal transducer, and configured to operate the module and provide communications to the module including repeating a signal for transmission downhole or uphole.

BACKGROUND

Hydrocarbons such as oil and gas are produced from reservoirs contained in earth formations. Boreholes drilled into the reservoirs are used to gain access to the hydrocarbons. Once a borehole is drilled, it is usually lined with a casing that is cemented in place, a screen or some other type of borehole liner. The hydrocarbons are then extracted from a reservoir and then flowed to the surface through the lined borehole.

Some formations may include multiple reservoirs or producing zones (several producing zones may be from the same reservoir) stacked one upon another. In these cases, one borehole may penetrate two or more of the stacked reservoirs or producing zones. Each reservoir or producing zone though may have different production characteristics such as an amount of water that is produced. In order to compensate for the different production characteristics, the flow from each reservoir needs to be controlled. Advancements in technology to improve flow control of fluids from reservoirs or producing zones, educe intervention cost, and improve flow efficiency would be well received in the drilling industry.

BRIEF SUMMARY

Disclosed is an apparatus for performing an operation in a borehole penetrating the earth. The apparatus includes: a downhole module configured to perform the operation and having an anchor device configured to anchor the module in the borehole, the anchor device being releasable in order to retrieve the module; a power source disposed on the module and configured to provide power to the module; a signal transducer disposed on the module and configured to at least one of transmit a wireless signal and receive a wireless signal; and a downhole electronic device disposed on the module, coupled to the signal transducer, and configured to operate the module and provide communications to the module including repeating a signal for transmission downhole or uphole.

Also disclosed is an apparatus for performing an operation in a borehole penetrating the earth includes: a downhole module configured to perform the operation and having an anchor device configured to anchor the module in the borehole, the anchor device being releasable in order to retrieve the module; a power source disposed on the module and configured to provide power to the module, the power source comprising a battery; a signal transducer disposed on the module and configured to at least one of transmit a wireless signal and receive a wireless signal; a downhole electronic device disposed on the module, coupled to the signal transducer, and configured to operate the module and provide communications to the module including repeating a signal for transmission downhole or uphole; an electromechanically actuated flow control valve coupled to the module and configured to receive a control signal using the signal transducer from a controller and to control flow through the valve based on the control signal; and a sensor coupled to the downhole electronics and configured to sense a parameter, the downhole electronic device being configured to transmit the wireless signal using the signal transducer, the wireless signal comprising a sensor reading.

Further disclosed is a method for performing an operation in a borehole penetrating the earth includes: disposing a downhole module in the borehole, the module being configured to perform the operation and having an anchor device configured to anchor the module in the borehole and to be released in order to retrieve the module, a power source disposed on the module and configured to provide power to the module, a signal transducer disposed on the module and configured to at least one of transmit a wireless signal and receive a wireless signal, and a downhole electronic device disposed on the module, coupled to the signal transducer, and configured to operate the module and provide communications to the module including repeating a received wireless signal for transmission downhole or uphole; anchoring the module in the borehole using the anchor device; and performing the operation using the module.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

FIG. 1 illustrates a cross-sectional view of an exemplary embodiment of downhole modules disposed in a borehole penetrating the earth;

FIGS. 2A-2C, collectively referred to as FIG. 2, depict aspects of the downhole modules;

FIG. 3 depicts aspects of a downhole module having a sensor; and

FIG. 4 is a flow chart for a method for performing an operation in a borehole penetrating the earth.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosed apparatus and method presented herein by way of exemplification and not limitation with reference to the figures.

Disclosed are apparatus and method for performing an operation or function in a borehole penetrating the earth. The operation is implemented by a downhole module that is conveyed through the borehole and anchored in the borehole at a specific location. Operational functions include flow control of fluid (e.g., performed by a valve operated remotely with several choke positions) extracted from a formation and to be flowed to the surface in the borehole and sensing one or more parameters such as fluid flow rate, pressure, temperature, vibration, and/or fluid characteristics. Additionally, the module includes communications capability using wireless signals to receive a flow control signal (e.g., to regulate percent of valve opened or completely close the valve) and to transmit sensed parameters to the surface. The communications capability includes providing repeater service to relay received wireless signals from either an uphole location (i.e., above the module) to a downhole location (i.e., below the module) or from a downhole location to an uphole location.

FIG. 1 illustrates a cross-sectional view of three downhole modules 10 disposed in a borehole 2 penetrating the earth 3 containing producing zones 4A and 4B. While FIG. 1 illustrates only two producing zones for teaching purposes, the teachings can apply to more than two producing zones with the additional zones being equipped with a wireless intelligent production module. The borehole 2 may be lined with a liner 5 such as a casing or screen or the borehole 2 may be unlined (i.e., open hole configuration) as non-limiting embodiments. Downhole module 10A is configured to be a repeater module for relaying wireless signals, if needed, while modules 10B and 10C are flow control modules configured to control the flow of corresponding reservoir fluid into and up the borehole 2. Reservoir fluid may enter the borehole 2 through perforations in a casing or screen if these liners are present.

Each module 10 may be conveyed through the borehole 2 by a carrier 6 such as a wireline 7 having a module interface. Other carriers may include segmented drill pipe or coiled tubing. Further each module 10 includes a module anchor 8 that is configured to anchor the module 10 to the liner 5 or directly to the borehole if a liner in not present. To anchor the module 10, the module anchor 8 includes extendable anchor elements 9. The extendable anchor elements 9 may be actuated by the carrier 6 using a mechanical linkage or some other configuration. In addition, the extendable anchor elements 9 may be retracted by the carrier 6 using the mechanical linkage or other configurations in order to move the module 10 to another location and or to remove the module 10 from the borehole.

In order to power operations, each module 10 includes a power source 13 that is configured to provide sufficient power to power the operation of the corresponding module 10. In one or more embodiments, the power source 13 includes a power accumulator 14 such as a battery or capacitor as non-limiting examples. In one or more embodiments, the power source 13 includes a turbine generator 15 configured to convert energy of borehole fluid flowing through the borehole to electrical energy that may be used to power module operations or to charge the power accumulator 14. Alternatively, a high capacity battery alone may be used to power the module operations.

Each module 10 includes wireless communications capability implemented by one or more signal transducers 11 and downhole electronics 12. Each signal transducer 11 is configured to convert an electrical signal to a wireless signal and/or a wireless signal into an electrical signal. Non-limiting embodiments of wireless signals include electromagnetic signals and acoustic signals. Accordingly, embodiments of a signal transducer 11 include an antenna and an acoustic transducer. In one or more embodiments, each module 10 is configured to provide repeater service to relay wireless signals to a nearby or adjacent module 10. In one or more embodiments, a module 10 may be configured to have two-way communications with a controller 16 disposed at the surface of the earth. The controller 16 may be implemented by a computer processing system as illustrated in FIG. 1. The controller 16 receives and transmits wireless signals using a surface signal receiver 17 that is disposed at or near the surface of the earth. The wireless signals may include a control signal for controlling operation of one or more modules 10 or a data signal for communicating data, such as sensor data or operational data, transmitted by one or more of the modules 10.

As noted above, the module 10 may be configured to control the flow of formation fluid into and up the borehole. As such, the module 10 may include a flow control valve 19. The flow control valve can be an open-close valve or a modulating valve that can modulate the flow through the valve to obtain a selected flow rate such as a percentage of the maximum flow capacity. The downhole electronics 12 are configured to receive a control signal from the controller 16 and to actuate the flow control valve based on the information in the control signal. In one or more embodiments, the flow control valve is actuated or operated by a solenoid for electromechanical valve operation. Other types of actuation may also be used.

When the module 10 includes the flow control valve 19, the module 10 may also include an expandable seal 18. The expandable seal 18 is configured to expand in order to seal against the borehole 2 or the liner 5. When expanded, the seal 18 isolates the borehole above the module 10 or the borehole below the module 10 from the borehole annulus surrounding the flow control valve 19. Hence, the seal 18 or seals 18 are configured to direct reservoir fluid flow from the reservoir into the flow control valve 19.

FIG. 2 depicts aspects of the downhole modules 10. FIG. 2A illustrates the modules 10A-C disposed downhole with valve modules 10B and 10C being disposed in separate reservoirs. As illustrated in FIG. 2B, the repeater module 10A includes an electronic transceiver 21 configured for relaying the wireless signals. The repeater module 10A also includes a battery 22 in the power accumulator 14. As illustrated in

FIG. 2C, the valve modules 10B and 10C include an electromechanically actuated flow control valve 23. The electrically actuated flow control valve is configured to use power from the power source 13 to actuate the valve 23 according to information received from a wireless control signal that was transmitted by the controller 16.

FIG. 3 depicts aspects of a downhole module 10 having a sensor 30. The sensor 30 may be disposed on the repeater module 10A and/or the valve module 10B or 10C. Alternatively, the sensor 30 may be incorporated into a downhole module dedicated as a sensor module 10D. In one or more embodiments, the sensor 30 may be a flow sensor configured to measure the flow rate of fluid flowing through the flow control valve 19, 23. Other non-limiting embodiments of the sensor 30 include valve position sensor, equipment operation sensor, temperature sensor, pressure sensor, optical transmissivity sensor, optical reflectivity sensor, flexural mechanical resonator sensor, permittivity sensor, dielectric constant sensor, viscosity sensor, conductivity sensor, acoustic velocity sensor, acoustic impedance sensor, corrosion sensor, and radiation sensor (both natural and neutron induced). Sensor measurements or readings are transmitted to the controller 16 using the wireless signal. The sensor data may then be processed by the controller 16 and sent to an output device such as a display or printer for displaying the data to a user or to a non-transitory computer readable medium for storage. Additionally, the controller 16 may be configured to send an alert signal to a user if any sensed data exceeds a threshold value.

FIG. 4 is a flow chart for a method for performing an operation in a borehole penetrating the earth. Block 41 calls for disposing a downhole module in the borehole, the module being configured to perform the operation and comprising: an anchor device configured to anchor the module in the borehole and to be released in order to retrieve the module, a power source disposed on the module and configured to provide power to the module, a signal transducer disposed on the module and configured to at least one of transmit a wireless signal and receive a wireless signal, and a downhole electronic device disposed on the module, coupled to the signal transducer, and configured to operate the module and provide communications to the module including repeating a received wireless signal for transmission downhole or uphole. Block 42 calls for anchoring the module in the borehole using the anchor device. The anchor device may be actuated by a carrier, such as a wireline or drill tubular, conveying the module in the borehole. Block 43 calls for performing the operation using the module. Non-limiting embodiments of the operation include (a) flow control of fluid entering the borehole from a reservoir using a remotely operated flow control valve that is controlled by a wireless control signal sent by a controller, (b) repeating wireless signals received from downhole or uphole, and (c) performing measurements of a parameter using a sensor disposed on the module and transmitting sensed data to the surface such as to the controller. Other types of operations may also be implemented using the module. The method 40 may also include modulating the flow through the flow control valve to achieve a selected flow rate (as measured by a flow sensor) using the control signal. The method 40 may also include releasing the anchor device and relocating the module. The releasing and relocating may be performed by the carrier.

The above disclosed apparatus and method provide several advantages. One advantage is that the downhole modules may be quickly deployed with commensurate lower cost due to avoiding the need to install, connect and maintain communications cable between modules and the surface controller. Another advantage is that a downhole module can be quickly retrieved for repair or replacement if a problem develops.

In support of the teachings herein, various analysis components may be used, including a digital and/or an analog system. For example, the downhole electronics 12, the controller 16 (or surface processing system 16), or the surface signal receiver 17 may include digital and/or analog systems. The system may have components such as a processor, storage media, memory, input, output, communications link, user interfaces, software programs, signal processors (digital or analog) and other such components (such as resistors, capacitors, inductors and others) to provide for operation and analyses of the apparatus and methods disclosed herein in any of several manners well-appreciated in the art. It is considered that these teachings may be, but need not be, implemented in conjunction with a set of computer executable instructions stored on a non-transitory computer readable medium, including memory (ROMs, RAMs), optical (CD-ROMs), or magnetic (disks, hard drives), or any other type that when executed causes a computer to implement the method of the present invention. These instructions may provide for equipment operation, control, data collection and analysis and other functions deemed relevant by a system designer, owner, user or other such personnel, in addition to the functions described in this disclosure.

Further, various other components may be included and called upon for providing for aspects of the teachings herein. For example, a, cooling component, heating component, magnet, electromagnet, sensor, electrode, transmitter, receiver, transceiver, antenna, controller, optical unit, electrical unit, electromechanical unit, or hydraulic unit may be included in support of the various aspects discussed herein or in support of other functions beyond this disclosure.

Elements of the embodiments have been introduced with either the articles “a” or “an.” The articles are intended to mean that there are one or more of the elements. The terms “including” and “having” are intended to be inclusive such that there may be additional elements other than the elements listed. The conjunction “or” when used with a list of at least two terms is intended to mean any term or any combination of terms. The term “configured” relates one or more structural limitations of a device that are required for the device to perform the function or operation for which the device is configured. The term “coupled” relates to a first component being coupled either directly to a second component or indirectly through an intermediate component.

The flow diagrams depicted herein are just examples. There may be many variations to this diagram or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.

While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.

It will be recognized that the various components or technologies may provide certain necessary or beneficial functionality or features. Accordingly, these functions and features as may be needed in support of the appended claims and variations thereof, are recognized as being inherently included as a part of the teachings herein and a part of the invention disclosed.

While the invention has been described with reference to exemplary embodiments, it will be understood that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications will be appreciated to adapt a particular instrument, situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 

What is claimed is:
 1. An apparatus for performing an operation in a borehole penetrating the earth, the apparatus comprising: a downhole module configured to perform the operation and comprising an anchor device configured to anchor the module in the borehole, the anchor device being releasable in order to retrieve the module; a power source disposed on the module and configured to provide power to the module; a signal transducer disposed on the module and configured to at least one of transmit a wireless signal and receive a wireless signal; and a downhole electronic device disposed on the module, coupled to the signal transducer, and configured to operate the module and provide communications to the module including repeating a signal for transmission downhole or uphole.
 2. The apparatus according to claim 1, wherein the wireless signal is an electromagnetic signal, an acoustic signal, or some combination thereof.
 3. The apparatus according to claim 2, wherein the signal transducer is an antenna, an acoustic transducer, or some combination thereof.
 4. The apparatus according to claim 1, further comprising a signal receiver disposed at or near the surface of the earth and configured to receive the wireless signal.
 5. The apparatus according to claim 4, the signal receiver is further configured to transmit the wireless signal to a controller configured to send a control signal to the module.
 6. The apparatus according to claim 1, wherein the power source comprises a battery.
 7. The apparatus according to claim 6, wherein the power source comprises a turbine generator configured to convert energy from a fluid flowing in the borehole into electrical energy to charge the battery.
 8. The apparatus according to claim 1, further comprising a flow control valve coupled to the module and configured to receive a control signal using the signal transducer from a controller and to control flow through the valve based on the control signal.
 9. The apparatus according to claim 8, wherein the controller is disposed at the surface of the earth.
 10. The apparatus according to claim 8, further comprising an expandable seal configured to isolate the control valve from the borehole annulus above or below the control valve.
 11. The apparatus according to claim 10, wherein the expandable seal comprises an upper expandable seal disposed above the flow control valve and a lower expandable seal disposed below the flow control valve.
 12. The apparatus according to claim 8, wherein the flow control valve is electromechanically actuated.
 13. The apparatus according to claim 1, further comprising a sensor coupled to the downhole electronics and configured to sense a parameter, the downhole electronic device being configured to transmit the wireless signal using the signal transducer, the wireless signal comprising a sensor reading.
 14. The apparatus according to claim 13, wherein the sensor is configured to sense a flow rate of fluid flowing through the flow control valve.
 15. An apparatus for performing an operation in a borehole penetrating the earth, the apparatus comprising: a downhole module configured to perform the operation and comprising an anchor device configured to anchor the module in the borehole, the anchor device being releasable in order to retrieve the module; a power source disposed on the module and configured to provide power to the module, the power source comprising a battery; a signal transducer disposed on the module and configured to at least one of transmit a wireless signal and receive a wireless signal; a downhole electronic device disposed on the module, coupled to the signal transducer, and configured to operate the module and provide communications to the module including repeating a signal for transmission downhole or uphole; an electromechanically actuated flow control valve coupled to the module and configured to receive a control signal using the signal transducer from a controller and to control flow through the valve based on the control signal; and a sensor coupled to the downhole electronics and configured to sense a parameter, the downhole electronic device being configured to transmit the wireless signal using the signal transducer, the wireless signal comprising a sensor reading.
 16. A method for performing an operation in a borehole penetrating the earth, the method comprising: disposing a downhole module in the borehole, the module being configured to perform the operation and comprising an anchor device configured to anchor the module in the borehole and to be released in order to retrieve the module, a power source disposed on the module and configured to provide power to the module, a signal transducer disposed on the module and configured to at least one of transmit a wireless signal and receive a wireless signal, and a downhole electronic device disposed on the module, coupled to the signal transducer, and configured to operate the module and provide communications to the module including repeating a received wireless signal for transmission downhole or uphole; anchoring the module in the borehole using the anchor device; and performing the operation using the module.
 17. The method according to claim 16, wherein the operation comprises repeating a received wireless signal using the downhole electronic device and the signal transducer.
 18. The method according to claim 16, further comprising receiving a wireless control signal from a controller disposed at the surface of the earth and controlling a flow control valve coupled to the module and configured to control flow through the valve based on the control signal.
 19. The method according to claim 18, further comprising modulating the flow through the flow control valve to achieve a selected flow rate using the control signal.
 20. The method according to claim 16, further comprising sensing a parameter with a sensor coupled to the module and transmitting a wireless signal comprising the sensed parameter using the signal transducer to a receiver disposed at or near the surface of the earth.
 21. The method according to claim 16, further comprising releasing the anchor device and relocating the module. 